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POLYTECHNIQUE MONTRÉAL Understanding the Control of Hazardous Energies on Machinery: Using Lockout and Alternative Methods in O

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POLYTECHNIQUE MONTRÉAL Understanding the Control of Hazardous Energies on Machinery: Using Lockout and Alternative Methods in O POLYTECHNIQUE MONTRÉAL affiliée à l’Université de Montréal Understanding the Control of Hazardous Energies on Machinery: Using Lockout and Alternative Methods in Organizations and Developing a Self- Audit Tool BENYAMIN KARIMI Département de mathématiques et de génie industriel Thèse présentée en vue de l’obtention du diplôme de Philosophiæ Doctor Génie industriel Novembre 2019 © Benyamin Karimi, 2019. POLYTECHNIQUE MONTRÉAL affiliée à l’Université de Montréal Cette thèse intitulée: Understanding the Control of Hazardous Energies on Machinery: Using Lockout and Alternative Methods in Organizations and Developing a Self- Audit Tool présentée par Benyamin KARIMI en vue de l’obtention du diplôme de Philosophiæ Doctor a été dûment acceptée par le jury d’examen constitué de : Daniel IMBEAU, Ph. D., président Yuvin Adnarain CHINNIAH, Ph. D., membre et directeur de recherche Damien BURLET-VIENNEY, Ph. D., membre et codirecteur de recherche Fabiano ARMELLINI, D.Sc., membre Gerard J. GOUW, Ph. D., membre externe iii DEDICATION To engineers and safety professionals iv ACKNOWLEDGEMENTS Completing this Ph.D. journey was not possible without the support of many individuals. I would like to first express my sincere thanks to my supervisor Prof. Yuvin Chinniah and my co- supervisor Dr. Damien Burlet-Vienney for their guidance and support by sharing personal and professional experiences. I would also like to thank my jury members, Prof. Daniel Imbeau, Prof. Gerard J. Gouw, and Prof. Fabiano Armellini for reviewing this dissertation and for their thoughtful comments. I would like to express my gratitude to all the organizations that participated in this work, and all the people who have been dedicated their time to support me in collecting data. I also acknowledge the NSERC (Natural Sciences and Engineering Research Council) and IRSST (Institut de recherche Robert-Sauvé en santé et en sécurité du travail) for funding this work. I am so grateful to my mother for her moral support. Finally and most importantly, I would like to heartily appreciate my wife Zara (Zara Farahnak). Words cannot express how grateful I am to her; for her full support and encouragement. v RÉSUMÉ Au Canada, comme dans de nombreux pays, les normes nationales et les réglementations provinciales exigent que les travailleurs œuvrant dans la zone dangereuse d’une machine pendant une phase de non-production suivent une procédure spécifique pour contrôler des énergies dangereuses. Si les énergies dangereuses de la machine ne sont pas contrôlées, il y a un risque de dégagement d'énergie, de mise sous tension ou de démarrage inattendu entraînant par conséquent des blessures ou décès. La norme canadienne CSA Z460 et la réglementation québécoise RSST décrivent les exigences en matière de contrôle des énergies dangereuses, appelées cadenassage (consignation ou lockout), ainsi que des méthodes alternatives lorsque le cadenassage ne peut pas être utilisé. Le nombre élevé d'accidents liés aux lacunes au niveau du contrôle des énergies dangereuses sur les machines démontre que les entreprises ont des difficultés avec l'application de ces exigences. En outre, l’absence d’audits du cadenassage ou d’outils pour l’audit de cadenassage est une réalité très répandue, de sorte que l’application du cadenassage n’est souvent pas entièrement conforme aux normes et aux réglementations. Au Québec, où cette étude a eu lieu, quatre décès et 1000 accidents se produisent en moyenne chaque année, en raison de l’absence ou des manquements aux procédures de cadenassage. Il existe peu d'études sur l'application réelle du cadenassage et elles se limitent en général à un secteur d’activité spécifique. Les outils disponibles pour auditer le cadenassage sont, pour leur part, incomplets. Par conséquent, les objectifs de cette thèse sont les suivants: premièrement, comprendre comment les entreprises mettent en œuvre des programmes et procédures de cadenassage, et dans quelle mesure ces programmes et procédures sont conformes à la norme CSA Z460 et à la réglementation en vigueur; et deuxièmement, concevoir un outil d’autodiagnostic pour auditer l’application des procédures de cadenassage sur la base des connaissances générées dans la première partie de l’étude. Pour atteindre le premier objectif, une étude terrain a été réalisée et un questionnaire complet (concernant le programme de cadenassage, l'application des procédures de cadenassage, les méthodes alternatives, la gestion des sous-traitants, la formation et l'audit / inspection) a été développé à cet effet. L'application du cadenassage et des méthodes alternatives a été étudiée dans 14 entreprises issues de divers secteurs d’activité du Québec par le biais d'une entrevue de vi groupe, d'une analyse documentaire et d'une observation du site dans chaque entreprise. Cette étape de l’étude a révélé que les pratiques de cadenassage en vigueur dans les entreprises visitées étaient meilleures que celles décrites dans leur programme de cadenassage. Cependant, un écart important a été constaté entre l’application du cadenassage et des méthodes alternatives et les exigences de la norme CSA et de la réglementation RSST. Les insuffisances constatées incluent: (i) des programmes de cadenassage incomplets; (ii) les étapes manquantes dans les procédures générales de cadenassage; (iii) les travailleurs ne lisent pas les fiches de cadenassage; (iv) le manque de connaissances sur les méthodes alternatives et la réglementation; (v) utiliser des méthodes alternatives sans évaluation des risques; (vi) formation insuffisante pour les méthodes alternatives; (vii) absence de supervision et de coordination des sous-traitants; (viii) et le manque d'outils d'audit et de documentation des résultats d'audit. L'étude a également proposé des recommandations (ex. mesures correctives) pour remédier aux lacunes identifiées. De plus, l’étude a révélé la nécessité de clarifier la norme canadienne et la réglementation québécoise sur l’utilisation de méthodes alternatives au cadenassage dans les organisations. Afin d'atteindre le deuxième objectif, un outil d’autodiagnostic pour auditer l'application des procédures de cadenassage sur des machines a été conçu sur la base des conclusions de l'étape précédente et des normes et réglementations en vigueur. Cet outil a été développé pour vérifier la préparation de cadenassage (ex. les conditions nécessaires) et aussi pour évaluer l’application des procédures de cadenassage. L'outil a ensuite été testé pour la validité du contenu via un panel d'experts et six entreprises du Québec. L'étude a démontré que le nouvel outil avait un indice de validité du contenu élevé, à la fois en termes d'indice de validité de contenu pour les éléments (I- CVI) et d'indice de validité de contenu pour l'outil (S-CVI). En outre, l’outil était facile à utiliser et son exhaustivité était suffisante pour contrôler l’application du cadenassage sur les machines par rapport aux exigences normatives et réglementaires. En effet, en utilisant cet outil, les organisations peuvent trouver et corriger les divergences dans l'application du cadenassage, améliorer les pratiques de cadenassage et garantir la sécurité des travailleurs. Cette thèse présente pour la première fois une étude sur l'application du cadenassage sur les machines dans les entreprises de différents secteurs. De plus, la thèse propose pour la première fois un outil d’autodiagnostic pour auditer l’application du cadenassage. vii ABSTRACT In Canada, like many countries, the national standard and provincial regulations require that workers working in the hazardous area of a machine during the non-production phase of machinery follow a specific safety procedure to control hazardous energies. Failure to control hazardous energies poses a risk of the release of energies, unexpected energization or start-up of machines (or equipment), hence resulting in injury or death. The Canadian Standard CSA Z460 and Quebec regulation ROHS describe the requirements for, and provide guidance on, the control of hazardous energies that is referred to as lockout, and also as alternative methods when lockout is not applicable. However, the high number of accidents linked to failure to control hazardous energies on machinery shows that organizations have difficulty with the application of lockout arrangements or the use of alternative methods. Moreover, the absence of audits of lockout or the lack of tools for auditing lockout is prevalent, and thus the application of lockout is often not fully in compliance with standards and regulations. In Quebec, where this study took place, four deaths and 1000 accidents on average occur annually due to either poor or the absence of, lockout procedures. Few studies exist on the actual application of lockout, but those are limited to a specific sector. Additionally, audit tools for the application of lockout are incomplete. Therefore, the objectives of this thesis are: first, to understand how organizations implement hazardous energy control programs and procedures, and the extent to which they are in accordance with relevant standards and regulations; and second, to design a self-audit tool for the application of lockout procedures on machinery based on the findings from the previous step. To attain the first objective, the qualitative study was conducted, and a comprehensive questionnaire (which is about the lockout program, application of lockout procedures, alternative methods, sub-contractor management, training, and audit/inspection) was developed. The application of lockout and alternative
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